Hybrid twist tray ice maker

ABSTRACT

An ice maker includes a harvest motor and an ice tray operably coupled to the harvest motor. The ice tray has a plurality of heat sinks coupled to a bottom section of ice forming cavities on the ice tray. The harvest motor is operable to twist the ice tray for causing the plurality of heat sinks to move relative to each other for releasing ice pieces from the ice forming cavities.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a continuation-in-part application of U.S.patent application Ser. No. 15/673,995 filed Aug. 10, 2017, now U.S.Pat. No. 10,309,707, entitled HYBRID TWIST TRAY ICE MAKER, which is acontinuation-in-part application of U.S. Pat. No. 9,746,229 granted Aug.29, 2017, entitled HYBRID TWIST TRAY ICE MAKER, the entire contents ofwhich are hereby incorporated herein by reference in their entireties.

FIELD OF THE INVENTION

The present disclosure generally relates to an ice tray for an icemaker, and more particularly to an ice maker having a twistable ice traythat includes a number of heat sinks attached to a lower portion thereoffor efficiently cooling a bottom surface of each ice forming cavity onthe ice tray, thereby promoting quick and efficient ice formation. Thepresent disclosure also relates to the corresponding methods ofoperating the ice maker and forming such an ice tray.

BACKGROUND OF THE INVENTION

It is generally understood that ice trays may be constructed with icecavities for making ice pieces in shapes and sizes convenient for auser's intended application, such as beverage cooling. Commonly, icetrays are formed entirely of polymeric materials to allow for twistingthe ice tray to release ice pieces. However, the polymeric materialsused for these ice trays typically have low thermal conductivity, whichcan result in slow freezing times for water introduced to the ice tray.In some instances, ice trays have been formed entirely of rigid metalmaterials, which provide little flexibility and make ice harvestingrelatively difficult.

SUMMARY OF THE PRESENT INVENTION

According to one aspect of the present disclosure, an ice tray includesa flexible structure having discrete ice forming cavities. A pluralityof heat sinks is coupled to the flexible structure. Each heat sink hasan upper portion that defines a bottom surface of at least one of theice forming cavities and a lower portion with at least one memberprotruding from the upper portion for distributing heat away from thebottom surface.

According to another aspect of the present disclosure, an ice makerincludes a harvest motor and an ice tray operably coupled to the harvestmotor. The ice tray has a plurality of heat sinks coupled to a bottomsection of ice forming cavities on the ice tray. The harvest motor isoperable to twist the ice tray for causing the plurality of heat sinksto move relative to each other for releasing ice pieces from the iceforming cavities.

According to yet another aspect of the present disclosure, a method offorming an ice tray includes providing a plurality of heat sinks, eachhaving an upper portion that defines a bottom surface of an ice formingcavity and a lower portion with at least one member protruding from theupper portion for distributing heat away from the bottom surface. Themethod also includes molding a flexible structure over a peripheral edgethe upper portion of each of the plurality of heat sinks to definesidewalls of the ice forming cavities. A seal is formed between theperipheral edge and the sidewalls to contain water in the ice formingcavities.

According to another aspect of the present disclosure, an ice trayincludes a flexible structure defining sidewalls of first and second iceforming cavities. The first and second heat sinks have an upper portiondefining a bottom surface of the respective first and second ice formingcavities and an upward protruding flange extending from the bottomsurface of each of the first and second ice forming cavities. Theflexible structure is molded around the upward protruding flange.

According to another aspect of the present disclosure, an ice makerincludes a harvest motor, a fan, and an ice tray operably coupled to theharvest motor. The ice tray has a flexible structure and a plurality ofheat sinks coupled to the flexible structure, wherein the heat sinks aredisposed at bottom portions of ice forming cavities of the ice tray. Theportions of the flexible structure are molded over portions of theplurality of heat sinks to form seals, and the harvest motor isselectively operable to twist the ice tray about a rotational axis sothat the flexible structure flexes. The plurality of heat sinks moverelative to each other to release ice pieces from the ice formingcavities. The fan is positioned to direct an airflow along the pluralityof heat sinks, and each of the plurality of heat sinks includes anexposed surface area that is configured to be exposed to the airflow. Afirst heat sink is located a first distance from the fan and defines afirst exposed surface area. A second heat sink is located a seconddistance from the fan and defines a second exposed surface area. Thefirst distance is less than the second distance, and the first exposedsurface area is less than the second exposed surface area.

According to another aspect of the present disclosure, an ice makerincludes a harvest motor, an axle member, and an ice tray operablycoupled to the harvest motor and the axle member. The ice tray has aflexible structure and a plurality of heat sinks coupled to the flexiblestructure, wherein the heat sinks are disposed at bottom portions of iceforming cavities of the ice tray. The harvest motor is selectivelyoperable to twist the ice tray about a rotational axis so that theflexible structure flexes and the plurality of heat sinks move relativeto each other to release ice pieces from the ice forming cavities. Theice tray may be agitated between a first position and a second positionin a rocking motion during ice formation. The plurality of heat sinksinclude a first heat sink with a first exposed surface area and a secondheat sink with a second exposed surface area. The first exposed surfacearea is not equal to the second exposed surface area.

These and other aspects, objects, and features of the present disclosurewill be understood and appreciated by those skilled in the art uponstudying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a top perspective view of a refrigerator that has arefrigeration compartment enclosable with doors, one door having an icedispenser, according to one embodiment;

FIG. 2 is a front elevational view of the refrigerator shown in FIG. 1,having the doors open to expose an ice storage compartment and an icemaker, according to one embodiment;

FIG. 3 is a top perspective view of an ice maker having an ice tray,according to one embodiment;

FIG. 4 is a top perspective view of the ice maker shown in FIG. 3,having portions of the ice maker housing shown in phantom lines toillustrate the ice tray operably engaged with a harvest motor;

FIG. 5 is a top perspective view of an ice tray, according to oneembodiment of the present disclosure;

FIG. 6 is a partially schematic bottom perspective view of the ice trayshown in FIG. 5, taken from an opposite end from that shown in FIG. 5;

FIG. 6A is a partially schematic bottom perspective view of an ice trayaccording to another aspect of the present disclosure;

FIG. 7 is a top plan view of the ice tray shown in FIG. 5;

FIG. 8 is a bottom plan view of the ice tray shown in FIG. 5;

FIG. 9 is an exploded top perspective view of the ice tray shown in FIG.5, illustrating a flexible portion of the ice tray separated from aplurality of heat sinks;

FIG. 10 is a top perspective view of an individual heat sink with anattachment feature, according to one embodiment;

FIG. 10A is a top perspective view of an individual heat sink having anadditional embodiment of an attachment feature;

FIG. 11 is a cross-sectional view of the ice tray, taken at line XI-XIof FIG. 7;

FIG. 11A is an enlarged view of a portion of the cross section shown inFIG. 11, taken at section XIA, illustrating a heat sink of the ice tray;

FIG. 11B is an enlarged view of a heat sink according to another aspectof the present disclosure;

FIG. 11C is an enlarged view of a heat sink according to another aspectof the present disclosure;

FIG. 12 is a cross-sectional view of the ice tray, taken at line XII-XIIof FIG. 7;

FIG. 12A is an enlarged view of a portion of the cross section shown inFIG. 12, taken at section XIIA, illustrating a heat sink of the icetray;

FIG. 13 is a top perspective view of an additional embodiment of an icetray, having heat sinks that span laterally between separate ice formingcavities;

FIG. 14 is a bottom perspective view of the additional embodiment of theice tray shown in FIG. 13;

FIG. 15 is an end view of the ice tray in the home position relative tothe ice maker housing;

FIG. 15A is a top perspective view of the ice tray shown in FIG. 15;

FIG. 16 is an end view of the ice tray in the rocked position relativeto the ice maker housing;

FIG. 16A is a top perspective view of the ice tray shown in FIG. 16;

FIG. 17 is an end view of the ice tray shown in a twisted positionrelative to the ice maker housing; and

FIG. 17A is a top perspective view of the ice tray shown in FIG. 17.

FIG. 18 is a perspective view of an ice tray according to another aspectof the present disclosure;

FIG. 19 is a bottom plan view of the ice tray of FIG. 18;

FIG. 20 is a perspective view of an ice tray according to another aspectof the present disclosure;

FIG. 21 is a perspective view of an ice tray according to another aspectof the present disclosure;

FIG. 22 is an end view of an ice tray in a rest position, a firstposition, and a second position relative to the ice maker housing; and

FIG. 23 is a top perspective view of an ice tray, illustrating heat flowproximate heat sinks.

DETAILED DESCRIPTION OF EMBODIMENTS

For purposes of description herein, the terms “upper,” “lower,” “right,”“left,” “rear,” “front,” “vertical,” “horizontal,” and derivativesthereof shall relate to the ice maker as oriented in FIG. 3. However, itis to be understood that the ice maker may assume various alternativeorientations, except where expressly specified to the contrary. It isalso to be understood that the specific devices and processesillustrated in the attached drawings, and described in the followingspecification are simply exemplary embodiments of the inventive conceptsdefined in the appended claims. Hence, specific dimensions and otherphysical characteristics relating to the embodiments disclosed hereinare not to be considered as limiting, unless the claims expressly stateotherwise.

Referring initially to FIGS. 1-2, a refrigerator 10 is depicted having arefrigeration compartment 12 situated above a freezer compartment 14.The illustrated embodiment of the refrigerator 10 is shown with a pairof doors 16 that are movable to enclose the refrigeration compartment12, whereby one of the doors 16 includes an ice storage container 18that delivers ice to an associated ice dispenser 20. The ice dispenser20 may be used for dispensing or otherwise removing ice from therefrigerator 10, and is typically accessible from the front side of thedoor 16 for use when the door 16 is in a closed position. The icestorage container 18 receives ice pieces from an ice maker 22 locatedabove the ice storage container 18 on the door 16. It is, however,contemplated that the ice maker 22 in other embodiments mayalternatively be located within the refrigeration compartment 12, thefreezer compartment 14, within any door of the appliance, or external tothe appliance, such as on a top surface of a refrigerator 10. Moreover,it is contemplated that the refrigerator 10 can be differentlyconfigured in alternative embodiments, such as with a single doorenclosing the refrigeration compartment 12, an ice storage containerwithout an ice dispenser, and the freezer compartment situated within,above, or on the side of the refrigeration compartment. Further, it isconceivable that the appliance associated with the ice maker 22 of thepresent disclosure may alternatively include a freezer appliance, acounter-top appliance, or other form of consumer appliance.

Referring now to FIGS. 3-17A, reference numeral 22 generally designatesan ice maker that includes a harvest motor 24 and an ice tray 26operably coupled to the harvest motor 24. The ice tray 26 has a flexiblestructure 28 and a plurality of heat sinks 30 coupled to a bottomsection of discrete ice forming cavities 32 on the ice tray 26. Eachheat sink 30 has an upper portion 34 that defines a bottom surface 36 ofat least one of the ice forming cavities 32 and a lower portion 38 withat least one heat dissipation member 40 protruding down from the upperportion 34. The heat dissipation member 40 of the heat sink 30 isconfigured to distribute heat away from the bottom surface 36 of thecorresponding ice forming cavity 32, thereby promoting quick andefficient ice formation, as well as the potential for unidirectionalsolidification of water for clear ice formation. After ice pieces haveformed in the ice forming cavities 32, the harvest motor 24 is operableto twist the ice tray 26 for causing the flexible structure 28 toelastically distort for releasing ice pieces, such that the plurality ofheat sinks 30 move relative to each other when the ice tray 26 istwisted. It is also contemplated that in another embodiment, the icetray 26 disclosed herein may be manually twisted by hand, without theuse of a harvest motor to release the ice pieces, while similarlyrealizing the benefits of quick and efficient ice formation.

With respect to the various methods of clear ice formation, it isgenerally appreciated that unidirectional solidification of water toform clear ice may be accomplished in various ways, including singletechniques and the combination of techniques. These techniques andmethods are described in more detail in U.S. patent application Ser. No.13/713,244 entitled “CLEAR ICE MAKER,” now U.S. Pat. No. 9,518,773issued Dec. 13, 2016, which is incorporated by reference herein in itsentirety. Accordingly, it is contemplated that additional embodiments ofthe illustrated ice maker 22 may include other features to promote clearice formation, such as agitation of the ice tray 26, warm aircirculation across the top surface of water in the ice forming cavities32, among other techniques to promote unidirectional solidification ofwater in the ice forming cavities 32.

As illustrated in FIGS. 3-4, the ice maker 22 includes the ice tray 26suspended across an interior volume of a housing 42 that substantiallyencloses the harvest motor 24 and the ice tray 26. The harvest motor 24is rigidly secured proximate a first end wall 44 of the housing 42 by apair of tabs 45 that extend from an upper region of the motor housing toengage horizontal slots in upper structural members 54 of the housing42. A first end 46 of the ice tray 26 is operably coupled with theharvest motor 24 and an opposing second end 48 of the ice tray 26 isrotatably coupled with a bearing aperture 50 in a second end wall 52 ofthe housing 42, opposite the first end wall. As such, a rotational axis53 of the ice tray 26 is defined between the points of attachment of thefirst and second ends 46, 48 of the ice tray 26. The first and secondend walls 44, 52 of the housing 42 are interconnected by structuralmembers 54, some of which have various attachment features for clips orother securing elements of the corresponding appliance or subcomponentsthereof to engage the ice maker and support the ice maker in the door 16of the refrigerator 10. The housing 42 provides a top opening 56 abovethe ice tray 26 to allow water to be injected into at least one of theice forming cavities 32 on the ice tray 26. Similarly, the housing 42includes a bottom opening 58 below the ice tray 26 to allow ice piecesto dispense from the ice maker 22 into the ice storage container 18. Itis understood that in additional embodiments, the housing 42 andarrangement of the ice tray 26 and harvest motor 24 with respect to thehousing 42 may be alternatively configured from the illustratedembodiment.

With reference to FIGS. 5 and 7, the illustrated embodiment of the icetray 26 includes two rows of discrete ice forming cavities 32 extendingin-line and on opposing sides of the rotational axis 53 of the ice tray26. The depicted rows of ice forming cavities 32 each include fiveindividual cavities, although it is contemplated that each row mayinclude more or fewer ice forming cavities 32 in additional embodimentsof the ice tray 26. Further, it is conceivable that additionalembodiments of ice forming tray 26 may include more rows, a single row,or another uniform or otherwise non-uniform distribution of ice formingcavities 32 on the ice tray 26. Each ice forming cavity 32 in theillustrated embodiment is defined by the bottom surface 36 and sidewallsurfaces 60 that extend upward from the bottom surface 36 to containwater accumulated on the bottom surface 36. The bottom surface 36 in thedepicted embodiment is substantially planar, although it is conceivablethat additional embodiments of the bottom surface 36 may be concave,convex, and may include other surface shapes or irregularities. Thedepicted ice forming cavities 32 are substantially cubed shaped,generally having four sidewall surfaces 60 that extend upward from thebottom surface 36 at locations that are substantially orthogonalrelative to each adjacent sidewall surface 60. The sidewall surfaces 60are interconnected by transition surfaces 62 that form curved corneredges of the ice forming cavity 32. The outermost sidewall surfaces 60of the ice tray 26 extend upward beyond the ice forming cavities 32 toform an upper ring 64 that surrounds all of the ice forming cavities 32and thereby defines an upper containment surface 66. Althoughsubstantially cubed shaped, each sidewall surface 60 angles outward fromthe respective bottom surface 36 to allow ice pieces to more easilyrelease from the ice tray 26 during the harvesting cycle, as discussedin more detail herein. The angled sidewall surfaces 60 may also provideadvantages in some embodiments of the ice maker 22, whereby the ice tray26 is rocked in oscillation about the rotational axis 53 to promoteclear ice formation, as also described in greater detail herein.

Still referring to FIGS. 5 and 7, the illustrated embodiment of the icetray 26 is provided with the flexible structure 28 that bounds thelateral sides of each of the ice forming cavities 32, thereby includingthe sidewall surfaces 60, the transition surfaces 62, and the uppercontainment surface 66. More specifically, the flexible structure 28defines a network of walls that interconnect with each other tosubstantially form the series of ice forming cavities 32. The walls inthe illustrated embodiment are defined as exterior sidewalls 68 thatsurround a periphery of the ice tray 26 and interior sidewalls 70 thatinterconnect inside of the exterior sidewalls 68 to form the ice formingcavities 32. Several of the interior sidewalls 70 that interconnectlinearly to extend along the rotational axis 53 of the ice tray 26 aretogether referred to as a median wall 72. The median wall 72 divides thetwo rows of ice forming cavities 32 in the illustrated embodiment, suchthat in some embodiments, rocking the ice tray 26 about the rotationalaxis 53 may cause the water in the ice forming cavities 32 to cascadeover the median wall 72 for promoting clear ice formation, as describedin more detail herein. It is contemplated that the flexible structure 28in alternative embodiments may include multiple interconnected flexiblepieces and may be alternately shaped to define ice forming cavities 32with different geometric configurations, such as semi-circular shapes,pyramid shapes, and other polygonal shapes. With respect to materialproperties, the flexible structure 28 may comprise a polymer configuredto have a low conductivity relative to the plurality of heat sinks 30.More specifically, the material forming the sidewall surfaces 60 of theice forming cavities 32 may include an insulated material, including,without limitation, plastic materials, such as polypropylene. Inaddition to being insulative, the material of the flexible structure 28may include an elastomeric polymer configured to resiliently twistduring the harvest cycle. Furthermore, portions of the sidewall surfaces60 and/or the interior surface of the ice forming cavities 32 mayinclude a coating, such as a hydrophobic or ice-phobic coating asdisclosed in U.S. patent application Ser. No. 13/782,746, filed Mar. 1,2013, entitled “HEATER-LESS ICE MAKER ASSEMBLY WITH A TWISTABLE TRAY,”now U.S. Pat. No. 9,513,045 issued Dec. 6, 2016, which is herebyincorporated by reference in its entirety.

With further reference to FIGS. 5 and 7, the ice forming cavities 32 arepartially interconnected by channels 74 formed through the interiorsidewalls 70. The channels 74, although capable of being formed asapertures or other types and shapes of conduits, in the illustratedembodiment are provided as narrow slots that allow water in the iceforming cavities 32 to flow into or out of an adjacent ice formingcavity 32 once water in the ice forming cavity 32 receiving water hasreached the level of the channel 74 on the respective interior sidewall70. Therefore, filling each of the ice forming cavities 32 with watermay be accomplished by adding or otherwise dispensing water into one ofthe ice forming cavities 32 and allowing the water to flow to theadjacent cavities 32 until each of the ice forming cavities 32 is filledto the desired level. It is also contemplated that additionalembodiments of the ice maker 22 may dispense water to more than one ofthe ice forming cavities 32, whereby the channels 74 may not be providedbetween the separate ice forming cavities 32 having dedicated waterdispensers. The channels 74 may also increase the flexibility of theflexible structure 28 by decreasing the structural rigidity that wouldresist twisting about the rotational axis 53.

As shown in FIGS. 5 and 6, the first and second ends 46, 48 of the icetray 26 are provided with attachment points to permit rotation about therotational axis 53. The second end 48 of the ice tray 26, as shown inFIG. 5, includes an axle member 76 that protrudes integrally away fromthe ice forming cavities 32 concentrically with the rotational axis 53.The axle member 76 is located centrally between the exterior sidewalls68 and in substantial alignment with the median wall 72. The axle member76 is configured to rotatably engage the bearing aperture 50 in thesecond end wall 52 of the housing 42 of the ice maker 22 (FIG. 4). It iscontemplated that additional embodiments of the axle member may be aseparate piece from the ice tray 26 and may be fixedly coupledtherewith, and it is conceivable that additional embodiments of the icemaker housing 42 may be provided with an axle member extending into theinterior volume from the second end wall 52 of the ice maker and,thereby, the second end 48 of the ice tray 26 may be provided with acorresponding bearing aperture for rotatably engaging such an axlemember.

The opposing first end 46 of the ice tray 26, as illustrated in FIG. 6,is similarly provided with an attachment point to permit rotation of theice tray 26 about the rotational axis 53. More specifically, the firstend 46 of the ice tray 26 includes a non-circular aperture 78 configuredto fixedly and matingly engage a corresponding non-circular end of arotor shaft of the harvest motor 24. The depicted embodiment includes asubstantially rectangular shaped aperture positioned on the first end 46to align the drive axis of the rotor shaft with the rotational axis 53of the ice tray 26, including alignment with the axle member 76 on thesecond end 48 of the ice tray 26. It is also conceivable that the firstend 46 of the ice tray 26 in additional embodiments may include an axlemember or a circular aperture that would allow for an alternativeoperable connection with the rotor shaft of the harvest motor 24 topermit rotation of the ice tray 26 in a similar manner.

Referring to FIGS. 6 and 8, the illustrated embodiment of the ice tray26 includes each of the plurality of heat sinks 30 coupled to a singlecavity of the discrete ice forming cavities 32, so that each ice formingcavity 32 has a dedicated heat sink 30 forming the bottom surface 36 ofthe ice forming cavity 32. The dedicated heat sinks 30 increase the rateof freezing of liquids in the ice cavities and are separately providedon each ice forming cavity 32 to not restrict and not substantiallyrestrict twisting and flexing of the flexible structure 28 of the icetray 26 to release ice pieces therein. One of the heat sinks 30 isthereby separate from at least one other heat sink 30 on the ice tray26, and more preferably each heat sink 30 is dedicated to an individualice forming cavity 32 to allow the greatest amount of flexing naturallypermitted by the material and construction of the flexible structure 28of the ice tray 26 upon twisting. The lower portion 38 of each of theheat sinks 30 includes at least one heat dissipation member 40protruding away from the upper portion 34, which defines the bottomsurface 36 of at least one of the ice forming cavities 32. The heatdissipation member 40 shown in the illustrated embodiment includes aseries of fins 80 that protrude downward from the upper portion 34 forconductively transferring heat away from the bottom surface 36 of therespective ice forming cavity 32 to air surrounding the series of fins80. In the depicted embodiment, the series of fins 80 are substantiallyplanar, aligned in parallel relationship to each other, and protrudingorthogonally from the substantially horizontal upper portion 34 of therespective heat sink 30. Further, the illustrated heat sinks 30 arepositioned relative to each other on the ice forming cavities 32 toalign the fins 80 of each heat sink 30 in perpendicular orientationrelative to the rotational axis 53 of the ice tray 26. By aligning thefins 80 of the heat sinks 30, air flow in a single direction may moreeasily pass through and between the fins 80, thereby more efficientlydissipating heat away from the bottom surface 36. It is contemplatedthat the heat dissipation member 40 may include more or fewer fins 80,alternatively shaped fins or other members, and fins or other membersprotruding in different orientations from the upper portion 34 of therespective heat sink 30.

Referring to FIG. 6, an electrically powered fan 41A may be utilized todirect airflow in the direction of arrow A1. Fins 80 of ice tray 26 aregenerally transverse (e.g., perpendicular) to rotational axis 53. Airflow parallel to the fins 80 (in the direction of arrow A1) carries heataway from the fins 80 to thereby promote rapid freezing of waterdisposed in cavities 32. The fluid flow may comprise fluid flow in thedirection of arrow A1. The fan 41A may be mounted to housing 42 or otherstructure of ice maker 22.

The fins 80 a may also be parallel to axis 53. Specifically, ice tray 26may include fins 80 a that are generally parallel to rotational axis 53as shown in FIG. 6A. An electrically powered fan 41B directs fluid (air)flow in the direction of arrow B1. Specifically, ice tray 26 may includefluid flow parallel to fins 80 a to carry heat away from fins 80 a. Fan41B may comprise a component of ice maker 22, and may be mounted tohousing 42 or other structure.

As further illustrated in FIG. 9, the plurality of heat sinks 30 areexploded away from the flexible structure 28 of the ice tray 26,exposing an upward protruding flange 82 that surrounds the upper portion34 of each heat sink 30. The upward protruding flange 82 is configuredto engage the flexible structure 28 around the respective ice formingcavity 32. The upward protruding flange 82 extends from an edge of asubstantially planar and horizontal surface of the heat sink 30 thatdefines the bottom surface 36 of the ice forming cavity. Accordingly,the upward protruding flange 82 extends from the bottom surface 36 insubstantial alignment with the sidewall surfaces 60 of the respectiveice forming cavity 32, but substantially outside the sidewall surfaces60 to allow material to encase the upward protruding flange 82 when itis embedded in the sidewalls 68, 70. The upward protruding flange 82, inthe illustrated embodiment, also includes at least one engagementfeature 84 to assist in retaining the respective heat sink 30 to theflexible structure 28. The engagement feature 84 may include variousforms of protrusions, apertures, adhesives, and/or fasteners configuredto engage the heat sink 30 to the flexible structure 28.

Two different embodiments of a heat sink 30 are illustrated in FIGS. 10and 10A, depicting different forms of engagement features 84 integrallyformed on the heat sink 30. As shown in FIG. 10, one embodiment of theengagement feature includes an aperture 86 formed through the upwardprotruding flange 82 in four locations spaced equally around the edge ofthe bottom surface 36. The apertures 86 have a substantially circularshape and extend between an inner surface 88 of the upward protrudingflange 82 and an outer surface 90 of the upward protruding flange 82 toallow injection molded material of the flexible structure 28 to flowinto the aperture 86 and, prior to solidification, interconnect materialabutting the inner surface 88 and material abutting the outer surface 90of the upward protruding flange 82. It is also contemplated that theadditional embodiments of flexible structure of the ice tray 26 may beformed to have a protrusion that is aligned for snap-fitting intoengagement with such an aperture 86 upon inserting the upward protrudingflange 82 into or onto a corresponding mating feature on the bottomportion of such a flexible structure, thereby similarly securing theheat sinks 30 around each of the ice forming cavities 32. It will beunderstood that the engagement features such as apertures 56 areoptional, and flange 82 may comprise a substantially continuousstructure that is free of apertures or other openings.

Another embodiment of the engagement feature 84 is shown in FIG. 10A,similar to the aperture 86 shown in FIG. 10, but a narrow passage 92 isformed in the upward protruding flange 82 that extends down from a topedge 94 of the upward protruding flange 82 to merge with an aperture 96in forming a tear-shaped notch 98. Similar to the aperture 86, the notch98 allows material to interconnect between the inner and outer surfaces88, 90 of the upward protruding flange 82 or otherwise to frictionallyengage a preexisting protrusion on the flexible structure 28. Theembodiment of the engagement feature 84 depicted in FIG. 10A providesthe narrow passage 92 with a smaller width proximate the top edge 94 ofthe upward protruding flange 82 than the interconnecting aperture 96having a larger width to define the tear-shaped notch 98. The largerwidth of the aperture assists in retaining the material of the flexiblestructure 28 in securing the heat sink 30 to the ice tray 26. It iscontemplated that additional, fewer and differently shaped notchesand/or apertures may be provided on the upward protruding flange 82 inother embodiments of the heat sink 30.

As further illustrated in FIGS. 10 and 10A, the outer surface 90 of theupward protruding flange 82 includes another embodiment of an engagementfeature 84, which is depicted as three retention ribs 100 that surroundthe outer surface 90 of the upward protruding flange 82. The retentionribs 100 are included to provide an additional feature for the injectionmolded material of the flexible structure 28 to engage for enhancing theconnection between the heat sinks 30 and the flexible structure 28. Inother embodiments the retention ribs 100 may be segmented or otherwiseprovided with different shapes and configurations to protrude from theinner and/or outer surfaces 88, 90 of the upward protruding flange 82for forming a sufficient connection.

The illustrated embodiment of the ice tray 26 shown in FIGS. 11-12Adepicts the flexible structure 28 injection molded over a peripheraledge 102 of the upper portion 34 of each of the plurality of heat sinks30 to define a seal between the bottom surfaces 36 of the ice formingcavities 32 and the sidewalls 68, 70 of the ice forming cavities 32. Theformation of the seal between the sidewalls 68, 70 and the heat sink 30is configured to retain water that comes into contact and accumulates onthe upper portion 34 of the heat sink 30. The flange 82 that surroundsthe peripheral edge 102 of each of the plurality of heat sinks 30 may besegmented in additional embodiments or otherwise consistent as shown inFIG. 10. To provide an adequate seal between the flexible structure 28and the heat sinks 30, additional material of the flexible structure 28may be provided around the upward protruding flange 82 on the heat sinks30 increasing the thickness of the sidewalls 68, 70 around the upwardprotruding flange 82 relative to the material provided along theinterior walls 70 that define the upper sections of the ice formingcavities 32.

Referring to FIG. 11B, a heat sink 30 a according to another aspect ofthe present disclosure, does not include fins, but rather has a bottomsurface 31 that is substantially smooth and planar. Bottom surface 31may, alternatively, be concave, convex, and may include other surfaceshapes or irregularities.

Referring to FIG. 11C, a heat sink 30 b according to another aspect ofthe present disclosure includes a plurality of longer fins 80 b that aresubstantially similar to fins 80. Heat sink 30 b also includes aplurality of shorter fins 80 c. Longer fins 80 b and shorter fins 80 cmay be arranged in an alternating manner as shown in FIG. 11C. However,virtually any suitable configuration may be utilized as shown in FIG.11C, longer fins 80 b may have a length L and shorter fins 80 c may havea length L₁. Fins 80 b and 80 c may be arranged in various orientations,lengths (L, L₁, etc.), and sizes to provide heat transfer from water inice forming cavity 32. Length L may be about twice the length L₁. Forexample, length L may be about 1-2 cm, and length L₁ may be about 0.5-1cm. It will be understood that the notches 98 of FIGS. 11B and 11C areoptional.

An additional embodiment of an ice tray 26 is shown in FIGS. 13 and 14,having heat sinks 104 that span between more than one ice forming cavity32. As shown, the heat sinks 104 span laterally across the rotationalaxis 53 thereby defining the bottom surface 36 of two laterally adjacentice forming cavities 32. These heat sinks 104 are also capable of movingrelative to each other upon twisting of the flexible structure 28 torelease ice pieces from the ice tray 26. As exemplified with thisembodiment, the heat sinks in additional embodiments of the ice tray 26may span beyond a single ice forming cavity 32 to couple with other iceforming cavities 32 or portions thereof. However, it is preferable foran embodiment of the ice tray 26 configured to twist for ice harvestingto include at least two separate heat sinks to permit twisting of theice tray 26, although the separate heat sinks may be pivotally orotherwise moveably coupled to each other.

Referring to FIGS. 15-17A, operation of the ice maker 22 is shownaccording to one embodiment. It is contemplated that the ice maker 22 isoperated by an electrical control unit or controller, either dedicatedto the ice maker 22 or otherwise integrated with another controller,such as the general control circuitry of the corresponding appliance. InFIGS. 15-15A the ice tray 26 is positioned horizontally in a homeposition 106 to allow water to be dispensed into the ice formingcavities 32. As water is dispensed into one of the ice forming cavities32, the water accumulates in that filling cavity 32 until the topsurface exceeds the height of the channels 74 that interconnect thefilling cavity 32 into other ice forming cavities 32 on the ice tray 26.Water then is permitted to communicate from the filling ice formingcavity 32 to the adjacent ice forming cavities 32, and then water isaccumulated in those adjacent ice forming cavities until either thewater is further distributed to the next sequential ice forming cavity32 or until all the ice forming cavities 32 are filled to the desiredlevel, such as a fill level below the top surfaces of the interior walls70.

As shown in FIGS. 16-16A the ice tray 26 is rotated to an angle thatwill allow the water to move in the ice forming cavities 32, if notalready frozen. From such a tilted angle, the ice tray 26 may then berotated in the opposite direction to an opposing tilted angle, which maythen be repeated to oscillate the ice tray 26 in a rocking motion.Rocking the ice tray 26 is an optional processing technique that may bedone with the ice maker 22 while water is freezing in the ice formingcavities to prevent the upper surface of the water from freezing beforethe remaining water, thereby promoting clear ice formation with the icemaker 22.

Once the water has substantially frozen to form ice pieces in the iceforming cavities 32, as shown in FIGS. 17-17A, the ice maker 22 mayoperate a harvest cycle. The harvest cycle commands the harvest motor 24to rotate the ice tray 26 about the rotational axis 53 to an invertedposition 108, whereby some of the ice pieces may fall out of the iceforming cavities 32 due to gravity. For the ice pieces that remainlodged in the ice forming cavities 32, the harvest motor 24 may continueto apply torque to the first end 46 of the ice tray 26 while the secondend 48 abuts a catch 110 on the second end wall 52 of the ice makerhousing 42, causing the flexible structure 28 of the ice tray 26 totwist. More specifically, the catch 110 abuts a protrusion on the secondend 48 of the flexible structure 28 of the ice tray 26 adjacent to theaxle member 76. The twisting of the ice tray 26 occurs in the flexiblestructure 28 generally about the rotational axis 53, which slightlydistorts the sidewalls 68, 70 and causes the ice pieces to dislodge andrelease from the ice forming cavities 32. The twisting of the flexiblestructure 28 is easily permitted due to the separation of the pluralityof heat sinks 30, which move relative to each other during the twistingmotion. It is contemplated that the twisting motion may also beaccomplished in additional embodiments of the ice maker 22 by rotatingthe ice tray 26 in an opposite direction from that illustrated,additionally or alternatively rotating the ice tray from the oppositeend, and/or twisting the ice tray in an oscillating or repeated cycle.

The heat sinks 30, 30 a, and 30 b may be aluminum or other suitablematerial. In general, aluminum heat sinks 30, 30 a, and/or 30 b and theflexible structure 28 are coupled together to form ice tray 26. Thealuminum heat sinks 30, 30 a, and/or 30 b and the flexible structure 28are coupled in a manner that forms a seal that remains intact when theice tray 26 is twisted. The aluminum heat sinks 30, 30 a, and/or 30 bconduct heat away from the water within the ice forming cavities 32 ofthe ice tray 26 by drawing heat away from the water at the bottomsurface 36 of the ice forming cavities 32. The flexible structure 28 maybe formed of a flexible material (for example, a polymer) that may haverelatively low thermal conductivity that limits heat transfer from thewater to the flexible structure 28. The use of relatively rigid aluminumheat sinks 30, 30 a, and/or 30 b coupled to a flexible polymer structure28 provides both increased heat transfer for rapid ice formation and icetray flexibility that allows ice cubes to be readily removed.

Referring to FIGS. 18-23, an ice tray 26 a may include heat sinks 30with exposed surface areas 120 a-120 c having various sizes and/orconfigurations. Like previously described and shown with reference toice tray 26, the ice tray 26 a may have a flexible structure 28 and aplurality of heat sinks 30 coupled to a bottom section of discrete iceforming cavities 32 on the ice tray 26 a. As previously explained, thefan 41A may be mounted to housing 42 or other structure of the ice maker22. An exposed surface area 120 may refer to a surface area of a heatsink 30 that is configured to be exposed to airflow from electricallypowered fan 41B or 41A. One or more heat sinks 30 a may include anexposed surface area 120 a. Exposed surface area 120 a may besubstantially smooth and planar. Alternatively, the exposed surface area120 a may be concave, convex, and may include other surface shapes andirregularities. One or more heat sinks 30 c may include three downwardextending fins 80. Heat sink 30 c may include an exposed surface area120 b. One or more heat sinks 30 d may include six downward extendingfins 80. Heat sink 30 d may include an exposed surface area 120 c. Assuch, the exposed surface area 120 a of a heat sink 30 a is less thanthe exposed surface area 120 b of a heat sink 30 b. The exposed surfacearea 120 b of a heat sink 30 c is less than the exposed surface area 120c of a heat sink 30 d. The equation q=hA(T₁−T₂) generally provides theoverall heat transfer rate from the heat sinks 30 to the airflow. Thevariables in the equation q=hA(T₁−T₂) may be defined as follows: h isthe heat transfer coefficient of the heat sink material, A is thesurface area where the heat transfer takes place, T₂ is the temperatureof the surrounding fluid (airflow), and T₁ is the temperature of thesolid surface (exposed surface area 120 of heat sink 30).

With reference to FIGS. 18 and 19, the heat sinks 30 a, 30 c, 30 d maybe arranged so that that the exposed surface areas (120 a, 120 b, 120 c)of each of the heat sinks 30 (including heat sinks 30 a, 30 c, 30 d)progressively increase as a distance (D₁, D₂, D₃, D₄, D₅) from theelectrically powered fan 41B of each of the of the heat sinks 30progressively increases.

Each heat sink 30 shown in FIGS. 18-23 may include an upward protrudingflange 82, as previously described and shown in the specification andfigures. The ice tray 26 a may be molded and/or otherwise formed aroundthe heat sinks 30 shown in FIGS. 18-23 in substantially the same manneras previously described and shown in the specification and figures.Additionally, the ice tray 26 a shown in FIGS. 18-23 may function insubstantially the same ways as the ice tray 26 previously described andshown in the specification and figures. That is, the ice tray 26 a shownin FIGS. 18-23 may operate as previously described and shown during theice formation, ice harvesting, and other ice maker 22 functions.

With continued reference to FIGS. 18 and 19, heat sinks 30 may bedisposed at progressive distances from electrically powered fan 41B.Heat sinks 30 a may be disposed at distances D₁, D₂ from electricallypowered fan 41B. Heat sinks 30 c may be disposed at distance D₃ from theelectrically powered fan 41B. Heat sinks 30 d may be disposed atdistances D₄ and D₅ from electrically powered fan 41B. The heat sinks 30a, 30 c, 30 d may be positioned in a substantially linear arrangement124 parallel to the axle member 76 of the ice maker 22.

With reference to FIGS. 18 and 19, during the ice forming process, theheat sinks 30 a, 30 c, 30 d transfer heat from the water 122 undergoingice formation (FIG. 23) in the ice forming cavities 32 to the airflowfrom the electrically powered fan 41B in the direction shown by arrowB1. To aid the transfer of heat from the water 122 undergoing iceformation in ice forming cavities 32 to the airflow, it may beadvantageous to minimize airflow obstructions along the airflow path.Airflow may flow along the exposed surface areas 120 a of the heat sinks30 a. Air may flow around the downward extending fins 80 of heat sinks30 c and 30 d. To reduce or minimize the obstruction of airflow alongheat sinks 30 c and 30 d, the fins 80 of heat sinks 30 c and 30 d may bearranged parallel to the airflow direction B1. Additionally, to furtherreduce or minimize obstruction of airflow along heat sinks 30 c and 30d, the distance d₁ between fins 80 of heat sinks 30 c may be less thanthe distance d₂ between fins 80 of heat sinks 30 d. Heat sinks 30 c mayinclude three downward extending fins 80. Heat sinks 30 d may includesix downward extending fins 80.

Referring to FIGS. 18, 19, and 23, as the airflow from electricallypowered fan 41B moves from the heat sinks 30 a closest to the fan 41B tothe heat sinks 30 d furthest from the fan 41B, the temperature of theairflow may increase. Therefore, increasing the exposed surface areas ofthe heat sinks 30 a, 30 c, 30 d as the respective distances D₁, D₂, D₃,D₄, and D₅ increase may contribute to maintaining a steady heat transferrate q from the heat sinks 30 a, 30 c, 30 d to the airflow. A steadyheat transfer rate q from the heat sinks 30 a, 30 c, 30 d to the airflowmay aid in ice formation at a generally uniform rate in ice formingcavities 32.

Referring now to FIG. 20, ice tray 26 a is shown with the fan 41Apositioned to move air along a substantially linear arrangement 124 a ofheat sinks 30 transverse to the axle member 76. Referring to FIG. 20,ice tray 26 a is shown with electrically powered fan 41A that directsairflow in the direction of arrows A1. Airflow carries heat away fromthe exposed surface areas 120 a of heat sinks 30 a and the exposedsurface areas 120 b of heat sinks 30 c. Airflow parallel to the downwardextending fins 80 of heat sink 30 c (in the direction of arrow A1)carries heat away from the downward extending fins 80 of heat sink 30 c.As such, the heat sinks 30 a and 30 c are arranged sequentially so thatthe airflow from the fan 41A sequentially absorbs heat from heat sink 30a and heat sink 30 c. That is, the exposed surface areas 120 a, 120 b ofthe respective heat sinks 30 a, 30 c progressively increase as thetransverse distance (T₁, T₂) from the fan 41A to the heat sinks 30 a, 30c increases.

Referring now to FIG. 21, ice tray 26 a is shown with heat sinks 30 cand 30 d arranged in a substantially linear arrangement 124 a of heatsinks 30 transverse to the axle member 76. Airflow carries heat awayfrom the exposed surface areas 120 b of heat sinks 30 c and the exposedsurface areas 120 c of heat sinks 30 d. Airflow parallel to the downwardextending fins 80 of heat sink 30 c (in the direction of arrow A1)carries heat away from the downward extending fins 80 of the heat sink30 c. Airflow parallel to the downward extending fins 80 of heat sink 30d (in the direction of arrow A1) carries heat away from the downwardextending fins 80 of the heat sink 30 d. As such, the heat sinks 30 cand 30 d have been arranged sequentially so that the airflow from thefan 41A sequentially absorbs heat from heat sink 30 c and heat sink 30d. That is, the exposed surface areas 120 b, 120 c of the respectiveheat sinks 30 c, 30 d progressively increase as the transverse distance(T₁, T₂) from the fan 41A to the heat sinks 30 c, 30 d increases.

Referring now to FIG. 22, an ice maker 22 that may rock during the iceforming process is shown. In the example shown, the ice tray 26 a mayrock between a first position I and a second position II to aid iceformation at a generally uniform rate in ice forming cavities 32. Theice tray 26 a may pivot about axle member 76. The ice tray 26 a is shownin a rest position III, a first position I, and a second position II. Inone example, in the first position I, the ice tray 26 a may be rotatedapproximately 30 degrees in a first direction from the rest positionIII. In one example, in the second position II, the ice tray 26 a may berotated approximately 30 degrees in a second direction from the restposition III. The continuous movement of the ice tray 26 a between thefirst position I and the second position II may be described as rocking.Rocking of the ice tray 26 a may promote unidirectional solidificationof water 122 in the ice forming cavities 32.

As previously explained and as shown in FIGS. 16 and 16A, the ice tray26 is rotated to an angle that will allow the water 122 to move in theice forming cavities 32, if not already frozen. From such a tiltedangle, the ice tray 26 may then be rotated in the opposite direction toan opposing tilted angle, which may then be repeated to oscillate theice tray 26 in a rocking motion. Rocking the ice tray 26 is an optionalprocessing technique that may be done with the ice maker 22 while water122 is freezing in the ice forming cavities 32 to prevent the uppersurface of the water 122 from freezing before the remaining water,thereby promoting clear ice formation with the ice maker 22.

Referring to FIG. 22, it is contemplated that the heat sinks 30 arrangedin a substantially linear arrangement 124 parallel to the axle member 76of the ice maker 22 may be used in an ice tray 26 a that rocks between afirst position I and a second position II during the ice formationprocess. It is contemplated that the substantially linear arrangement124 of heat sinks 30 in the ice tray 26 a having greater exposed surfaceareas 120 as the distance D from the electrically powered fan 41B to theheat sinks 30 increases may allow for steady heat transfer from the heatsinks 30 to the airflow during an ice formation process that includesrocking of the ice tray 26 a between the first and second positions I,II.

Referring to FIG. 23, heat transfer (represented by arrows 126) from theheat sinks 30 a, 30 c, and 30 d to the airflow from fan 41B in thedirection of arrow B1 is shown. As previously explained with referenceto ice tray 26, the heat sinks 30 a, 30 c, and 30 d may be metal (e.g.,aluminum). The metal (e.g., aluminum) heat sinks 30 a, 30 c, and 30 dmay be thermally conductive. As previously stated with reference to icetray 26, the flexible structure 28 of the ice tray 26 a may be made of aflexible polymeric material. The flexible structure 28 may be made of amaterial that may have a lower coefficient of thermal conductivity thanthe material of the heat sinks 30 a, 30 c, and 30 d. The ice tray 26 amay be made of a material that may have a lower coefficient of thermalconductivity than the material of the heat sinks 30 a, 30 c, and 30 d.Thus, the ice tray 26 a may be made from a material having greaterflexibility than the material of the heat sinks 30 a-30 d, but thematerial of heat sinks 30 a-30 d may have greater heat transfer (highercoefficient of thermal conductivity) than the material of the ice tray26 a. As such, the materials utilized in the ice tray 26 a, the flexiblestructure 28, and the heat sinks 30, as well as the sizes of the exposedsurface areas 120 of the heat sinks 30 may contribute to the maintenanceof a steady heat transfer rate q from the heat sinks 30 to the airflowduring the ice formation process.

It will be understood that the surface to air heat transfer capabilityof surface ares 120 of heat sinks 30 may be increased or decreasedutilizing other approaches such as different fin lengths/heights,increasing/decreasing surface irregularities, fin shape, fin length,etc.

It will be understood by one having ordinary skill in the art thatconstruction of the described ice maker and other components is notlimited to any specific material. Other exemplary embodiments disclosedherein may be formed from a wide variety of materials, unless describedotherwise herein.

For purposes of this disclosure, the term “coupled” (in all of itsforms, couple, coupling, coupled, etc.) generally means the joining oftwo components (electrical or mechanical) directly or indirectly to oneanother. Such joining may be stationary in nature or movable in nature.Such joining may be achieved with the two components (electrical ormechanical) and any additional intermediate members being integrallyformed as a single unitary body with one another or with the twocomponents. Such joining may be permanent in nature or may be removableor releasable in nature, unless otherwise stated.

It is also important to note that the construction and arrangement ofthe elements shown in the exemplary embodiments is illustrative only.Although only a few embodiments of the present innovations have beendescribed in detail in this disclosure, those skilled in the art whoreview this disclosure will readily appreciate that many modificationsare possible (e.g., variations in sizes, dimensions, structures, shapesand proportions of the various elements, values of parameters, mountingarrangements, use of materials, colors, orientations, etc.) withoutmaterially departing from the novel teachings and advantages of thesubject matter recited. For example, elements shown as integrally formedmay be constructed of multiple parts or elements shown as multiple partsmay be integrally formed, the operation of the interfaces may bereversed or otherwise varied, the length or width of the structuresand/or members or connector or other elements of the system may bevaried, the nature or number of adjustment positions provided betweenthe elements may be varied. It should be noted that the elements and/orassemblies of the system may be constructed from any of a wide varietyof materials that provide sufficient strength or durability, in any of awide variety of colors, textures, and combinations. Accordingly, allsuch modifications are intended to be included within the scope of thepresent innovations. Other substitutions, modifications, changes, andomissions may be made in the design, operating conditions, andarrangement of the desired and other exemplary embodiments withoutdeparting from the spirit of the present innovations.

It will be understood that any described processes or steps withindescribed processes may be combined with other disclosed processes orsteps to form structures within the scope of the present disclosure. Theexemplary structures and processes disclosed herein are for illustrativepurposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can bemade on the aforementioned structures and methods without departing fromthe concepts of the present disclosure, and further it is to beunderstood that such concepts are intended to be covered by thefollowing claims, unless these claims by their language expressly stateotherwise.

In various embodiments, the invention may be characterized in variousclauses and various combinations thereof, including the followingparagraphs:

An ice tray comprises a flexible structure defining sidewalls of firstand second ice forming cavities and first and second heat sinks havingan upper portion defining a bottom surface of the respective first andsecond ice forming cavities. An upward protruding flange extends fromthe bottom surface of each of the first and second ice forming cavities,wherein the flexible structure is molded around the upward protrudingflange.

An ice tray, wherein the first heat sink is disposed a first distancefrom a fan, and the second heat sink is disposed a second distance fromthe fan. The first distance is less than the second distance.

An ice tray, wherein the first heat sink includes a first exposedsurface area, and the second heat sink includes a second exposed surfacearea. The first exposed surface area is less than the second exposedsurface area.

An ice tray, wherein the first exposed surface area includes a bottomsurface that is one or more of the following: substantially planar,concave, or convex.

An ice tray, wherein the second exposed surface area includes one ormore downward extending fins.

An ice tray, wherein the first exposed surface area includes one or moredownward extending fins, and the second exposed surface area includesone or more downward extending fins.

An ice tray further comprising a third ice forming cavity, wherein theflexible structure defines sidewalls of the first, second, and third iceforming cavities. A third heat sink has an upper portion defining abottom surface of the respective third ice forming cavity and an upwardprotruding flange extending from the bottom surface of each of thefirst, second, and third ice forming cavities, wherein the flexiblestructure is molded around the upward protruding flange.

An ice tray, wherein the first heat sink is disposed a first distancefrom the fan, the second heat sink is disposed a second distance fromthe fan, and the third heat sink is disposed a third distance from thefan. The first distance is less than the second distance, and the seconddistance is less than the third distance.

An ice tray, wherein the first heat sink has a first exposed surfacearea, the second heat sink has a second exposed surface area, and thethird heat sink has a third exposed surface area. The first exposedsurface area is less than the second exposed surface area, and thesecond exposed surface area is less than the third exposed surface area.

The ice tray, wherein the first exposed surface area includes a bottomsurface that is one or more of the following: substantially planar,concave, or convex. The second exposed surface area includes one or moredownward extending fins, and the third exposed surface area includes oneor more downward extending fins.

An ice tray, wherein the second exposed surface area includes aplurality of downward extending fins, and the third exposed surface areaincludes a plurality of downward extending fins. The distance betweenthe downward extending fins of the second exposed surface area isgreater than the distance between the downward extending fins of thethird exposed surface area.

An ice tray, wherein the ice tray includes a first end coupled to aharvest motor and a second end coupled to a bearing aperture, wherein arotational axis is defined between the first end and the second end. Oneor more downward extending fins of the first exposed surface area andone or more downward extending fins of the second exposed surface areaare arranged parallel to the rotational axis so that airflow parallel tothe rotational axis flows between the one or more downward extendingfins of the first exposed surface area and the one or more downwardextending fins of the second exposed surface area and carries heat awayfrom the one or more downward extending fins of the first exposedsurface area and the one or more downward extending fins of the secondexposed surface area.

An ice tray includes a first end coupled to a harvest motor and a secondend coupled to a bearing aperture, wherein a rotational axis is definedbetween the first end and the second end. One or more downward extendingfins of the first exposed surface area and one or more downwardextending fins of the second exposed surface area are arrangedtransverse to the rotational axis so that airflow parallel to therotational axis flows between the plurality of fins and carries heataway from the plurality of fins.

An ice maker, comprising a harvest motor, a fan, and an ice trayoperably coupled to the harvest motor. The ice tray has a flexiblestructure and a plurality of heat sinks coupled to the flexiblestructure, wherein the heat sinks are disposed at bottom portions of iceforming cavities of the ice tray. Portions of the flexible structure aremolded over portions of the plurality of heat sinks to form seals. Theharvest motor is selectively operable to twist the ice tray about arotational axis so that the flexible structure flexes and the pluralityof heat sinks move relative to each other to release ice pieces from theice forming cavities. The fan is positioned to direct an airflow alongthe plurality of heat sinks. Each of the plurality of heat sinksincludes an exposed surface area that is configured to be exposed to theairflow. A first heat sink is located a first distance from the fan anddefines a first exposed surface area, and a second heat sink is locateda second distance from the fan and defines a second exposed surfacearea. The first distance is less than the second distance, and the firstexposed surface area is less than the second exposed surface area.

An ice maker, wherein the plurality of heat sinks comprise the firstheat sink including a bottom surface that is one or more of thefollowing: substantially planar, concave, or convex. The second heatsink including a bottom surface having one or more fins, and a thirdheat sink including a bottom surface having two or more fins. The firstheat sink is closest to the fan, the second heat sink is furthest fromthe fan, and the second heat sink is at an intermediate distance fromthe fan and between the first heat sink and the third heat sink. Theexposed surface area that is configured to be exposed to the airflow ofeach of the plurality of heat sinks progressively increases as adistance from the fan of each of the plurality of heat sinksprogressively increases.

An ice maker, wherein the first heat sink includes a pair of first heatsinks, and the third heat sink includes a pair of third heat sinks.

An ice maker, wherein each of the pair of third heat sinks includes morefins than the second heat sinks.

An ice maker, comprising a harvest motor, an axle member, and an icetray operably coupled to the harvest motor and the axle member. The icetray has a flexible structure and a plurality of heat sinks coupled tothe flexible structure, wherein the heat sinks are disposed at bottomportions of ice forming cavities of the ice tray. The harvest motor isselectively operable to twist the ice tray about a rotational axis sothat the flexible structure flexes. The plurality of heat sinks moverelative to each other to release ice pieces form the ice formingcavities. The ice tray may be agitated between a first position and asecond position in a rocking motion during ice formation. The pluralityof heat sinks include a first heat sink with a first exposed surfacearea and a second heat sink with a second exposed surface area. Thefirst exposed surface area is not equal to the second exposed surfacearea.

An ice maker, further comprises a fan, wherein the first heat sink andthe second heat sink are positioned in a substantially lineararrangement parallel to or transverse to the axle member. The fansuccessively directs an airflow along the first heat sink and the secondheat sink. The first exposed surface area of the first heat sink is lessthan the second exposed surface area of the second heat sink. A firstheat transfer rate from the first heat sink to the airflow issubstantially equal to a second heat transfer rate from the second heatsink to the airflow.

An ice maker, wherein the first heat transfer rate from the first heatsink to the airflow during ice formation is substantially equal to thesecond heat transfer rate from the second heat sink to the airflowduring ice formation.

What is claimed is:
 1. An ice tray, comprising: a flexible structure defining sidewalls of first and second ice forming cavities; and first and second heat sinks having an upper portion defining a bottom surface of the respective first and second ice forming cavities, and an upward protruding flange extending from the bottom surface of each of the first and second ice forming cavities, wherein the flexible structure is molded around the upward protruding flange.
 2. The ice tray of claim 1, wherein: the first heat sink is disposed a first distance from a fan; the second heat sink is disposed a second distance from the fan; and the first distance is less than the second distance.
 3. The ice tray of claim 2, wherein: the first heat sink includes a first exposed surface area; the second heat sink includes a second exposed surface area; and the first exposed surface area is less than the second exposed surface area.
 4. The ice tray of claim 3, wherein: the first exposed surface area includes a bottom surface that is one or more of the following: substantially planar, concave, or convex.
 5. The ice tray of claim 3, wherein: the first exposed surface area includes one or more downward extending fins; and the second exposed surface area includes one or more downward extending fins.
 6. The ice tray of claim 5, wherein: the ice tray includes a first end coupled to a harvest motor and a second end coupled to a bearing aperture; wherein a rotational axis is defined between the first end and the second end; and wherein the one or more downward extending fins of the first exposed surface area and the one or more downward extending fins of the second exposed surface area are arranged parallel to the rotational axis so that airflow parallel to the rotational axis flows between the one or more downward extending fins of the first exposed surface area and the one or more downward extending fins of the second exposed surface area and carries heat away from the one or more downward extending fins of the first exposed surface area and the one or more downward extending fins of the second exposed surface area.
 7. The ice tray of claim 5, wherein: the ice tray includes a first end coupled to a harvest motor and a second end coupled to a bearing aperture, and wherein a rotational axis is defined between the first end and the second end, and the one or more downward extending fins of the first exposed surface area and the one or more downward extending fins of the second exposed surface area are arranged transverse to the rotational axis so that airflow parallel to the rotational axis flows between the plurality of fins and carries heat away from the plurality of fins.
 8. The ice tray of claim 4, wherein: the second exposed surface area includes one or more downward extending fins.
 9. The ice tray of claim 1, further comprising: a third ice forming cavity, wherein the flexible structure defines sidewalls of the first, second, and third ice forming cavities; and a third heat sink having an upper portion defining a bottom surface of the respective third ice forming cavity, and an upward protruding flange extending from the bottom surface of each of the first, second, and third ice forming cavities, and wherein the flexible structure is molded around the upward protruding flange.
 10. The ice tray of claim 9, wherein: the first heat sink is disposed a first distance from the fan; the second heat sink is disposed a second distance from the fan; the third heat sink is disposed a third distance from the fan; the first distance is less than the second distance; and the second distance is less than the third distance.
 11. The ice tray of claim 10, wherein: the first heat sink has a first exposed surface area; the second heat sink has a second exposed surface area; the third heat sink has a third exposed surface area; the first exposed surface area is less than the second exposed surface area; and the second exposed surface area is less than the third exposed surface area.
 12. The ice tray of claim 11, wherein: the first exposed surface area includes a bottom surface that is one or more of the following: substantially planar, concave, or convex; the second exposed surface area includes one or more downward extending fins; and the third exposed surface area includes one or more downward extending fins.
 13. The ice tray of claim 12, wherein: the second exposed surface area includes a plurality of downward extending fins; the third exposed surface area includes a plurality of downward extending fins; and the distance between the downward extending fins of the second exposed surface area is greater than the distance between the downward extending fins of the third exposed surface area.
 14. An ice maker, comprising: a harvest motor; a fan; and an ice tray operably coupled to the harvest motor, the ice tray having a flexible structure and a plurality of heat sinks coupled to the flexible structure, wherein the heat sinks are disposed at bottom portions of ice forming cavities of the ice tray; wherein portions of the flexible structure are molded over portions of the plurality of heat sinks to form seals; wherein the harvest motor is selectively operable to twist the ice tray about a rotational axis so that the flexible structure flexes and the plurality of heat sinks move relative to each other to release ice pieces from the ice forming cavities; wherein the fan is positioned to direct an airflow along the plurality of heat sinks; wherein each of the plurality of heat sinks includes an exposed surface area that is configured to be exposed to the airflow; and wherein a first heat sink is located a first distance from the fan and defines a first exposed surface area, and wherein a second heat sink is located a second distance from the fan and defines a second exposed surface area, and wherein the first distance is less than the second distance and the first exposed surface area is less than the second exposed surface area.
 15. The ice maker of claim 14, wherein: the plurality of heat sinks comprise: the first heat sink including a bottom surface that is one or more of the following: substantially planar, concave, or convex; the second heat sink including a bottom surface having one or more fins; and a third heat sink including a bottom surface having two or more fins, wherein the first heat sink is closest to the fan, the second heat sink is furthest from the fan, the second heat sink is at an intermediate distance from the fan and between the first heat sink and the third heat sink, and wherein the exposed surface area that is configured to be exposed to the airflow of each of the plurality of heat sinks progressively increases as a distance from the fan of each of the plurality of heat sinks progressively increases.
 16. The ice maker of claim 15, wherein: the first heat sink includes a pair of first heat sinks; and the third heat sink includes a pair of third heat sinks.
 17. The ice maker of claim 16, wherein: each of the pair of third heat sinks includes more fins than the second heat sink.
 18. An ice maker, comprising: a harvest motor; an axle member; an ice tray operably coupled to the harvest motor and the axle member, the ice tray having a flexible structure and a plurality of heat sinks coupled to the flexible structure, wherein the heat sinks are disposed at bottom portions of ice forming cavities of the ice tray; wherein the harvest motor is selectively operable to twist the ice tray about a rotational axis so that the flexible structure flexes and the plurality of heat sinks move relative to each other to release ice pieces from the ice forming cavities; wherein the ice tray may be agitated between a first position and a second position in a rocking motion during ice formation; and wherein the plurality of heat sinks include a first heat sink with a first exposed surface area and a second heat sink with a second exposed surface area, and wherein the first exposed surface area is not equal to the second exposed surface area.
 19. The ice maker of claim 18, further comprising: a fan; wherein the first heat sink and the second heat sink are positioned in a substantially linear arrangement parallel to or transverse to the axle member; wherein the fan successively directs an airflow along the first heat sink and the second heat sink; wherein the first exposed surface area of the first heat sink is less than the second exposed surface area of the second heat sink; and wherein a first heat transfer rate from the first heat sink to the airflow is substantially equal to a second heat transfer rate from the second heat sink to the airflow.
 20. The ice maker of claim 19, wherein: the first heat transfer rate from the first heat sink to the airflow during ice formation is substantially equal to the second heat transfer rate from the second heat sink to the airflow during ice formation. 